Engineer - Mechanical

Aditya Birla Group

Gummidipoondi, India

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Job Description

Job Purpose

To Plan, Execute and monitor the Mechanical Maintenance activities of all 5 production lines in order to achieve the trouble free and smooth operation of the plant.

Job Context & Major Challenges

Job Context: Birla Carbon, Gummidipoondi unit was commissioned in 1998 and since then has been progressively expanded to 5 production lines, to reach its current annual production capacity of approximately 2,37,250 MT of carbon black. It is the largest carbon black manufacturing unit in India, and amongst the top 3 largest manufacturing units for Birla Carbon globally. In addition to carbon black, the unit has power generation (co-product of carbon black manufacturing) capacity of 60.7 MW and also rubber master batch (downstream product for carbon black) capacity of approximately 15,000 MT per annum. Birla Carbon, Gummidipoondi has implemented a management system which meets all requirements of various standards including IATF 16949:2016, ISO 14001:2004, OHSAS 18001:2007 to manage Quality, Environment, Occupational Health & Safety. Power generation and export is a major value driver. The unit has 60.7 MW power generation capacity, part of which is used to meet the requirements of unit and the balance is exported to the network. This role is accountable for the execution and maintenance of all the rotating and stationary mechanical equipment for producing carbon black and generation of power to ensure continuous availability of equipment for uninterrupted production of carbon black. This is also accountable for meeting the regulatory compliance pertaining to the above.
Major Challenges: Reduction in breakdowns and improved uptime of plant and all machineries. Reduction in planned shutdowns and downtime to increase OEE & OPE. Improving the environmental performances by avoiding emissions, leakages etc. Reduction in Repair & Maintenance Cost. Manpower planning during plant S/D or preventive maintenance. Regulatory Compliances.

Key Result Areas

	KRA (Accountabilities) (Max 1325 Characters)	Supporting Actions (Max 1325 Characters)
KRA1	Mechanical Maintenance: Execution of Mechanical maintenance activities to achieve trouble free operation.	Planning and scheduling to attend any break down or shut down. Execution of jobs in shut down and breakdown as per planning. Effective utilization of man power so as job completed within time. Co-ordination with production and concerned dept. during shut down and break down. Maintain cleanliness after maintenance activities. Proper utilization of spares and Control wastage of spares during Mechanical maint.
KRA2	Preventive Maintenance: Monitoring and execution of preventive maintenance to reduce break down and maint. cost.	Execution of preventive maint of equipment's as per schedule and requirement. Identify various abnormalities in rotating equipment's and suggest proper solution. Monitoring of consumption of spare regularly. Monitoring of In house fabrication of critical spares/Equipment.
KRA3	System Management: Implementation of maintenance management system to perform quality maintenance.	Documentation to fulfil compliance of IATF: 16949:2016, and ISO: 14001. Follow procedure & work instruction related to Mech. maint. during break down and planned maint. Participation in Internal and External Auditing System. Preparation of procedure and work instruction related to mechanical maint. required by system.
KRA4	Safety: Implement Global Safety Standard and its procedure & legal compliance to create safe working condition.	Documentation to fulfil compliance of OHS :18001. Execution of pressure vessel testing for statutory requirement. Importing of on job safety training. Task observation of workmen during critical job for assurance of safe working.
KRA5	Training and Development: Participate in teams through various initiatives to raise competency level.	Participation in QC, KSS, 5S & WCM activities and shop floor. meeting. Imparting training on various Preventive maint. activities. Clarify work procedure on shop floor.
KRA6	Spare parts Management: Ensure availability of spares for trouble free operation of plant.	Identify the critical spares. Maintaining minimum spare part of critical equipment. Plan and monitor procurement action for all spares and other materials for all Line Includes line # 4A and 4B. Co-ordination with Purchase & store dept. to optimize inventory level.
KRA7	Continual Improvement: Continuous up-gradation of Mechanical systems for their efficient and uninterrupted operation.	Work out all technical and commercial aspects of modification and proposed benefits expected. Planning complete Project works and identification of critical and floating activities. Mobilization of resources. Review & monitoring of work progress. Resulting completion of job within time. Initiate for various improvement projects.
KRA8	Capex: Execution of capex and new projects.	Execution of Mechanical capex projects.